US4769951A - Door made of plastic material for motor vehicles - Google Patents

Door made of plastic material for motor vehicles Download PDF

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Publication number
US4769951A
US4769951A US06/843,693 US84369386A US4769951A US 4769951 A US4769951 A US 4769951A US 84369386 A US84369386 A US 84369386A US 4769951 A US4769951 A US 4769951A
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US
United States
Prior art keywords
door
motor vehicles
frame
window
profiled frame
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
US06/843,693
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English (en)
Inventor
Hans-Heinrich Kaaden
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Individual
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Individual
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/04—Doors arranged at the vehicle sides
    • B60J5/0401—Upper door structure
    • B60J5/0405—Inboard or outboard side of window frame formed integrally with the lower door structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/04—Doors arranged at the vehicle sides
    • B60J5/0463—Conceptual assembling of door, i.e. how door frame parts should be fitted together to form door
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/04—Doors arranged at the vehicle sides
    • B60J5/048—Doors arranged at the vehicle sides characterised by the material
    • B60J5/0481—Doors arranged at the vehicle sides characterised by the material plastic

Definitions

  • the invention relates to a door made of plastic material for motor vehicles, with a stiffening suitable for receiving the outer and inner shells of the door, said stiffening transmitting the forces occurring into the frame of the body of the vehicle.
  • the side door is a highly complicated component of the body of a motor vehicle.
  • the door has to have exceptionally high strength and is expected to function even after a collision accident.
  • a door made of steel sheet satisfies said requirements.
  • Efforts made to reduce the weight have resulted in door designs comprising a plastic outer shell of the door and a plastic inner shell of the door applied to a stiffening construction consisting of steel profiles or sections.
  • the forces acting on such a construction are transmitted into the frame of the auto body by the stiffening construction consisting of steel sections.
  • the outer and inner shells are manufactured by deep-drawing and combined with each other.
  • Said doors represent a combination of different materials; however, such doors do not meet the requirements in automobile construction particularly with respect to safety.
  • the present invention is based on the problem of further reducing the weight of a plastic door for motor vehicles and to construct such a door in such a way that it will fully satisfy all requirements without a stiffening construction made of steel sections while still having substantial safety reserves.
  • the stiffening designed as a supporting construction, the outer shell of the door and the inner shell of the door are formed by prefabricated plastic parts capable of being joined together and produced mainly by injection molding, whereby the supporting construction may be formed by a profiled frame extending all around and having a reinforcement injection-molded beneath the window opening.
  • the reinforcement injected in the profiled frame is formed by horizontally extending load profiles and vertically extending ribs in the form of a latticework construction.
  • Said load profiles may have any desired shape; however, advantageously, they have the shape of a "V", double "T” or "I" beam, or "U".
  • Said design provides a frame construction with torsional rigidity.
  • the load profiles permit the transmission of forces between the hinges and the zone of the locking mechanism.
  • the load profiles are kept in their horizontal position by the vertically extending ribs.
  • the latticework formed by the horizontally extending load profiles and vertically extending ribs represents a safety cell by which forces occurring in accidents are transmitted into the metal frame of the body of the vehicle.
  • the profiled frame has a cross section with the shape of a double "T” or "U".
  • Stiffening ribs extending parallel to the flanges are injected on both sides of the crosspiece of the double T-shaped profiled frame and on the crosspiece of the U-shaped profiled frame. Said stiffening ribs serve primarily for stiffening the profiled frame.
  • the outer shell of the door has an areal stiffening disposed on the inside of the shell, usefully, said stiffening has an asymmetric star shape with different wall thicknesses.
  • the outer side of the window pane is disposed approximately on one plane with the window facing and outer shell of the door. In this way, a low drag value is achieved within the zone of the window of the door and wind noise is largely avoided.
  • the invention provides a fully plastic door for motor vehicles that is produced mainly by injection molding. Said door offers a significant weight reduction and it meets or largely exceeds the safety requirements given for such doors.
  • a high-quality plastic door made by injection molding it is possible for the first time in auto body construction for the auto industry to construct the passenger cell as a genuine safety cell also as far as the sides are concerned.
  • a static flexural load of 3,000 kg is the requirement and standard with respect to the strength values of current door constructions made of auto body sheet.
  • the plastic door with the design of the invention which is manufactured primarily by injection molding from high-quality thermoplastics, is capable of withstanding a static flexural load in the range of 6,000 and 9,000 kg depending on the dimensions of the load profiles. This means that said plastic door assures a lateral construction of the passenger cell with high torsional rigidity. Thus a notable gain in safety is obtained as compared to conventional door constructions particularly in dangerous rear-and-front-end collisions.
  • plastics such as, for example, duroplastics or elastomers may be used partially for manufacturing the door, especially for producing the shells.
  • FIG. 1 shows a perspective view of a profiled frame with a latticework construction injection-molded therein, an outer shell of the door and an inner shell of the door partially shown in a sectional view prior to the assembly of said parts;
  • FIG. 2 is a perspective view of a variation of a profiled frame with a latticework construction injection-molded therein;
  • FIG. 3a is a sectional view of a T-shaped profiled frame within the zone of the window with a connected window facing including the window pane, as well as a glued-in window sealing strip;
  • FIG. 3b shows the same parts as FIG. 3a, but with a cut view within the zone of the window pane well;
  • FIG. 3c shows the same as FIG. 3a, but with a cut through the bottom zone
  • FIG. 4a is a sectional view of a U-shaped profiled frame within the zone of the window, with a connected window facing including the window pane and a glued-in door sealing strip;
  • FIG. 4b shows the same parts as FIG. 4a, but with a section through the zone of the window pane well;
  • FIG. 4c shows the same as FIG. 4a, but with a cut through the bottom zone
  • FIGS. 5a to 5c are sectional views of a variation based on FIGS. 3a to 3c;
  • FIGS. 6a to 6c show sectional views of a variation based on FIGS. 4a to 4c;
  • FIG. 7 is a perspective view of a variation based on FIG. 4a, with an especially large connection area between the window facing and profiled frame;
  • FIG. 8 is a perspective view of a variation based on FIG. 4a with a door facing on the profiled frame;
  • FIG. 9 is a perspective view of a lower main part of the supporting construction.
  • FIG. 10 shows a variation based on FIG. 4b with a separate plastic window frame
  • FIG. 11 is a variation based on FIG. 4b with a separate metal window frame
  • FIG. 12 shows a variation based on FIG. 4b, with a metal window frame representing another variation of 4b;
  • FIG. 13 shows a variation based on FIG. 4a for a door without a window frame.
  • FIG. 1 shows that a reinforcement 2 in the form of a latticework construction is molded by injection in a profiled frame 1 having a cross section with the shape of double "T” and extending all around.
  • Said reinforcement is formed by the horizontally extending load profiles 2' and the vertically extending ribs 2".
  • Said load profiles 2' may have any desired shape.
  • the load profiles 2' have a V-shaped section
  • FIG. 2 shows load profiles with a cross section in the shape of a double "T" or "I” beam.
  • the profiled frame 1 provides a frame construction with torsional rigidity forming with the reinforcment 2 the supporting construction of the door, which door is to be viewed as a door and safety cell.
  • the double "T" or “I” beam-shaped profiled frame 1 has the stiffening ribs 5 extending parallel to the flanges. Said ribs are injection-molded on both sides of the crosspiece and arranged with a uniform spacing between each other.
  • the outer side of the latticework construction 2' and 2" is recessed for guiding the window pane 11.
  • the guide strips 12 are arranged on the outwardly facing side of the latticework construction 2' and 2". Said strips 12 are made of plastic, too, and secured by glueing.
  • the outer shell 3 of the door is formed by a window facing 14, said facing having a Z-shaped cross section and being divided in the horizontal direction.
  • An areal stiffening 16 having the asymmetric shape of a star is disposed on the inner side of the outer door facing 3', said stiffening 16 having different wall thicknesses.
  • the latticework construction 2' and 2" projects beyond the profiled frame.
  • the inner legs 7 of said profiled frame are extended horizontally and vertically in the lower part of the supporting construction 1+2, forming a frame 8 on the inner side.
  • the latticework construction 2' and 2" and the profiled frame 1 may extend flush.
  • the frame 8 has the inwardly stepped steps 9.
  • the inner door facing 4 has a shaped cushion with a large rebound area which, in accidents, acts as an impact-reducing element. Said effect is increased by rubber buffers disposed between the rib constructions of the inner shell 4 of the door and the supporting construction 1 +2.
  • the arm rest 27 is integrated in the inner door facing 4.
  • the lock, handle and crank parts are arranged recessed for reasons of reducing the hazard of injury. If they are not arranged recessed, said parts are provided with an adequate rebound area.
  • the inner shell 4 of the door is usefully covered with a textile material.
  • the supporting construction formed by the profiled frame 1 and the reinforcement 2, the latter in turn being formed by the load profiles 2' and the vertical ribs 2" forming a latticework construction, can be prefabricated.
  • Said supporting construction and the outer shell 3 and the inner shell 4 of the door are manufactured by injection molding from high-quality modified thermoplastics.
  • the injection molding process offers nearly unlimited shaping possibilities, so that any type of shape can be produced per se.
  • the positions for installing the hinges, locks, centering devices and mirrors are injection-molded ready for the installation of said parts if possible in terms of molding techniques.
  • FIGS. 3a to 3c show a window facing 14 and an outer shell 3 arranged on different sectional panels on a T or "I" beam-shaped profiled frame 1.
  • the window facing 14 which has a Z-shaped section in said zone, accommodates a guide strip 12 having an angularly shaped section.
  • the plastic guide strip 12 has a U-shaped section, and the outer door shell facing 3' has a plane profile 15 extending all around on the side facing the supporting construction 1+2.
  • the outer door shell facing 3' is combined with the profiled frame 1 via said profile 15 by glueing or fusing.
  • Said plane profile 15 is reinforced within the zone of connection.
  • a door sealing strip 6 is glued into the inside of the profiled frame 1, extending all around and abutting the stiffening ribs 5 in a butt-joined connection. It is known that a decorative strip 29 is arranged on the window facing 14.
  • FIGS. 4a to 4c show another variation of the sectional shape of the profiled frame 1 with the matching arrangement of a window facing 14 and an outer door facing 3'.
  • stiffening ribs 5 are arranged in the U-shaped profiled frame 1.
  • a U-shaped metal profile may be arranged for guiding the window pane.
  • a lower main part 17 of the supporting construction 1+2 is shown, said part being associated with the part containing the zone of the window.
  • a clearance 18 is provided in each case for receiving a window frame forming the part containing the zone of the window.
  • Said window frame may be made of plastic material 19 or metal 19'.
  • the connection between the window frame 19 or 19' and the plastic main door part 17 may be established in any desired way, advantageously by means of screwing the parts together.
  • the plastic window frame 19 has a supporting profile 20 and a profile 21 for guiding the window pane, said profile 21 having the shape of a "U" and being glued into the supporting profile 20.
  • the metal window frame 19' consists of a supporting profile 20' and a profile 21' for guiding the window pane, with said supporting profile 20' being covered by a plastic cover profile 22 extending all around.
  • the window pane may be guided by a common metal frame 23.
  • the metal frame 23 has a U-shaped section in the zone of the window and additional installation legs 24 provided in the well of the window, said legs being screwed on the installation or mounting ribs 13 of the profiled frame 1.
  • the door is designed frameless within the zone of the window.
  • the window pane is guided on a plastic guiding profile 25 embedded in the frame of the door, as well as on a window-sealing strip 26 glued into the guiding profile 25.
  • the storage compartment 28 consists of plastic material and is usefully glued into the inner shell 4 of the door.
  • FIG. 1 shows that all required installation positions 10 are arranged in the inner shell 4 of the outer facing 3' of the door and in the supporting constructions 1+2.
  • the horizontal load profiles 2' and the vertically extending ribs 2" have reinforced and rounded ties provided on their joints and points of connection.
  • the plastic door according to the invention may be used for all types of motor vehicle, including its use as a hatch-type door.
  • the door represents a typical group of components manufactured from high-quality chemical materials.
  • chemical materials which are each selected for their specific properties, a light-weight door for auto bodies is provided which meets the most exacting safety requirements.
  • the load part i.e. the supporting construction
  • a modified thermoplastic material such as a modified type of polyamide 6 with or without filler.
  • high strength combined with high rigidity is required for the profiled load part, among other properties.
  • a mineral-filled duroplastic material or a modified thermoplastic in the form of a modified polybutylene teraphthalate (PBTP) with high impact strength is suitable, among other materials, for the outer shell of the door.
  • PBTP polybutylene teraphthalate
  • thermoplastic material such as, for example, polypropylene, or a PUR-material is suitable for the inner shell of the door.
  • said component has to assume also functions of interior or passive safety.
  • Technological progress, cost optimization combined with superior quality, improvements of the manufacturing process for facilitating the production operation and reduction of the production cost are the requirements to be satisfied for the mass production of light-weight body parts made from chemical materials.
  • Stubbe by developing a series of manufacturing machines for the mass production of auto body parts, has created a new technology for the construction of auto body parts from chemical materials that is meeting said requirements.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Window Of Vehicle (AREA)
  • Securing Of Glass Panes Or The Like (AREA)
  • Body Structure For Vehicles (AREA)
US06/843,693 1984-06-04 1985-05-31 Door made of plastic material for motor vehicles Expired - Fee Related US4769951A (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE3420744 1984-06-04
DE3420744 1984-06-04
DE19843423827 DE3423827A1 (de) 1984-06-04 1984-06-28 Tuer aus kunststoff fuer kraftfahrzeuge
DE3423827 1984-06-28

Publications (1)

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US4769951A true US4769951A (en) 1988-09-13

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
US06/843,693 Expired - Fee Related US4769951A (en) 1984-06-04 1985-05-31 Door made of plastic material for motor vehicles

Country Status (5)

Country Link
US (1) US4769951A (enrdf_load_stackoverflow)
EP (1) EP0214139B1 (enrdf_load_stackoverflow)
AT (1) ATE38805T1 (enrdf_load_stackoverflow)
DE (2) DE3423827A1 (enrdf_load_stackoverflow)
WO (1) WO1985005599A1 (enrdf_load_stackoverflow)

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Also Published As

Publication number Publication date
DE3566372D1 (en) 1988-12-29
WO1985005599A1 (en) 1985-12-19
DE3423827C2 (enrdf_load_stackoverflow) 1989-06-08
DE3423827A1 (de) 1985-02-14
EP0214139B1 (de) 1988-11-23
ATE38805T1 (de) 1988-12-15
EP0214139A1 (de) 1987-03-18

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